TrueMill® Training Manual

10/4/2006
TrueMill® Training Manual

Table of Contents
INTRODUCTION .................................................................................................................... 1
OPEN SOLIDWORKS FILE IN SURFCAM ............................................................................. 2
MACHINING OF THE PART .................................................................................................... 4
TRUEMILL® FOR POCKET FEATURE ................................................................................. 5
TRUEMILL® FOR STEP FEATURE .................................................................................... 14
TOOLPATH VERIFICATION .................................................................................................. 17
DETERMINING MACHINING PARAMETERS FOR TRUEMILL® ................................................ 19
TRUEMILL® SAMPLE TESTING RESULTS ............................................................................. 20

®
TrueMill is a registered trademark of Surfware, Inc.

Copyright© 2007 by Surfware, Inc.

This manual is protected by U.S. copyright, international treaties, and other applicable copyright laws and may not be
reproduced, distributed or sold without the express permission of Surfware, Inc., which reserves all rights. Reuse of any of
Surfware content and graphics for any purpose without Surfware’s permission is strictly prohibited.

While every precaution has been taken in the preparation of this manual, Surfware assumes no responsibility for errors or
omissions, or for damages resulting from the use of the information contained herein

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TrueMill® Training Manual

Introduction
TrueMill® is the best roughing software for most applications and materials. TrueMill is proven to
increase profits by dramatically reducing machine cycle times. Longer cutting tool life and higher
quality parts are also a benefit of TrueMill.

Traditional high-speed machining uses smaller depths of cut and stepovers than regular tool
paths. In dramatic contrast, TrueMill enables even greater depths of cut and stepovers at higher
feeds and spindle speeds.

TrueMill maximizes the capabilities of your existing CNC equipment as follows:

• TrueMill dynamically controls the tool’s engagement with the material to create fluid tool
paths and eliminate spikes or sudden changes in tool load.
• This steady tool engagement enables much more aggressive spindle speeds, feedrates,
depth of cut, and stepover. Use speeds, depths, and stepovers that would damage the
part or break the tool if used with traditional tool paths.
• These aggressive parameters greatly reduce cycle times.
• This steady engagement dramatically reduces tool wear and the smooth efficient manner
in which material is removed is also easier on the machine which lowers machine
maintenance costs.
• Higher quality parts are also inherent with TrueMill. More heat is transferred to the chip,
away from the part, resulting in much less part deformation.

Included with this manual is the example file used in the manual. Please create a folder named
Training Manual in the \SURFCAM\Samples\ folder as shown below. Then uncompress/unzip
the provided files in this folder.

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TrueMill® Training Manual

Open SolidWorks file in SURFCAM

The part that is used in this section was created in SolidWorks. The file was saved in the
SolidWorks native format, with the SLDPRT extension.

To open the SolidWorks file in SURFCAM click on File, Open and browse to the
\SURFCAM\Samples\Training Manual folder.

Set the Files of Type to SolidWorks Files (*prt,*sldprt) and select TrueMill.sldprt

The native SolidWorks file gets loaded in SURFCAM. Click on the Shaded with Wireframe

button. Then switch to Isometric view by holding Ctrl + 7.

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If you check the Layers dialog box, you can see that SURFCAM automatically placed the surface
and the wireframe elements on two separate layers:

To change the options that apply to SolidWorks files, click Tools, Options and then select Files,
Read, SolidWorks/Parasolid

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TrueMill® Training Manual

Machining of the Part

This part has a Pocket and a Step feature that will be machined by using the TrueMill®
technology.

TrueMill is Surfware’s high-speed machining solution for any machine tool. TrueMill® enables the
tool to maintain higher speeds because all abrupt direction changes are replaced with smooth,
tangent tool motion. Smooth high-speed repositioning moves also replace the rapid moves,
allowing the machine to stay in the high-speed mode continuously during the entire cycle.
Because of these enhancements, toolpath feed rates can be increased and cycle times reduced.

The tool engagement angle (TEA) is a key setting in TrueMill. SURFCAM creates the toolpath so
that the actual engagement angle of the tool never exceeds the value you specify.

Tool Engagement Angle = 90º

You create a TrueMill operation the same way you create the conventional Pocket and Contour
operations. However, the TrueMill pocketing option creates a superior tool path.

In the sections below we discuss the machining of each of the part’s features.

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TrueMill® for Pocket Feature

Click on NC, 2 Axis, TrueMill

Make sure that the selection mode is

set to Chain

Select the pocket boundaries by clicking twice on 1. The selected chain changes its color. Then
select Done

The TrueMill dialog gets displayed. Click on the Select Tool button and select 0.5 dia - 2 flute –
Endmill

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Click on the Select Material button, select 6061-T6 Aluminum and click OK on the Select
Material dialog.

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Click on the Common to > tab and set the parameters as shown. Since we selected Aluminum,
we will use machining settings that are suitable for this material. Remember, TrueMill enables
you to use more aggressive spindle speeds, feedrates, depth of cut, and stepover.

In this section we focus on the settings that are critical to create an optimum TrueMill toolpath:

Geometry is the: select the top radio button

Choose the option that matches the profile you select to create the
operation.

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Set Depth to 0.5

This setting specifies the total depth of the cutting operation.

You can also use the Pick Z Depth button to specify

the depth of a pocket

When you click this button , the dialog box is removed temporarily and the Select
Point menu is displayed. The Elements command is displayed and highlighted.
If you select the vertical line, the
difference between the values of the
Z coordinates of its end points
becomes the Depth.

Minimum Radius
Use a minimum radius to avoid excessive small movements, especially in sharp corners.
This reduces inefficient motion during a radial cut, thus saving machine time and
reducing tool wear.

Example:
Minimum Radius = 0 Minimum Radius = 0.25
might produce excessive small radial cuts reduces unnecessary radial cuts

Plunge Type: click on the Helix button

You can set the Helix Radius and the Ramp
Angle of the helical plunge move.

Accept the default values.

Set High Feed Rate to 800 IPM

The High Feed Rate is to the maximum linear (not rapid) feed rate value of your CNC
machine. Every positioning move (between engagements) is done at this high feed rate
as opposed to a rapid move.

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The TrueMill toolpath contains both rough and finish cuts. As shown below, you can set different
feed rates and spindle speeds for Roughing and Finishing.

Set Feed Rate (rough) to 650 IPM

Set Feed Rate (finish) to 400 IPM

Set Spindle Speed (rough) to 12,000 RPM

Set Spindle Speed (finish) to 10,000 RPM

Click on the Rough/Finish tab

You can notice three groups of settings that apply to the different cuts: Rough, Finish Floor and
Finish Walls.

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1. Rough settings

Set Maximum Depth to 0.5

The actual cutting depth is less than or equal to this value. The operation divides the
total depth into equal depth passes. For example, if the Depth is 0.5 inches and you set
Maximum Depth of Cut to 0.2 inches, it creates 3 equal depth passes of 0.1667 inches.

Set Tool Engagement to 120 degrees

The tool engagement angle (TEA) is a key setting in TrueMill. SURFCAM creates the
toolpath so that the actual engagement angle of the tool never exceeds the value you
specify regardless of the part’s shape. The Tool Engagement and Maximum Stepover
settings work together. Set one to dynamically calculate the other.

Set Stock to Leave on Walls to 0.01 in

Stock to Leave on Walls determines the amount of material that remains on the walls
after the Rough cut. Check the Finish Walls option (see below) to remove this material.

Set Lead In/Out Radius to 0.05 in

This is the radius of the rough cutting moves
into and out of the material. The arrow
indicates a lead-out move.

Set Helix Clearance to 0.005 in

The radius moves before and after engagement with the material are helical. This is done
so the tool does not drag across the surface of the material. Helix Clearance is the
distance in Z between the start and the end of these helix moves.

The picture above indicates a helical radius move, where the helix clearance takes place.

This is a top view close-up of the helical radius move.

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This is the side view. The arrows indicate the Helix Clearance.

Tip: If you want an arc instead of a helical move, set the Helix
Clearance to 0.

Set Engagement Clearance to 0.01 in

This is the linear distance from the material to the tool where the feed rate changes
between the High Feed Rate and the Feed Rate.

This feed rate change may take place part way through a helical Lead In/Out move.

The High Feed Rate moves in the lower left corner are
shown in bold line type. The arrows indicate the
Engagement Clearance.

2. Finish Floor settings

Clear the Finish Floor setting. In this example we do not finish the floors.

Note: Typically you increase the finish Tool Engagement Angle to finish the floor. If you don’t
need to manage the Tool Engagement Angle on the floor, you can create a subsequent
traditional pocket operation.

3. Finish Walls settings

Select the Finish Walls check box
This option creates a finish cut on the walls.

Select the Make One Cut at Net check box

Check this box to make one finish pass that leaves no stock on the walls.

Select the Make 1 Spring Cut check box

Check this box to create 1 or more additional cutting passes at net (no stock).
Clear the Cutter Compensation check box

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Check this box to create cutter compensation moves before the lead-in and after the
lead-out moves for Finish Walls. In the illustration below, the Cutter Compensation
moves are shown in bold line type. The arrows indicate the Cutter Compensation
Distance.

OFF ON

The Cutter Compensation Move can be perpendicular or tangent.

Set Final Finish Cut Overlap to 0.05 in

Use this setting to prevent a mark left by lead-in and lead-out moves at the same
location. The final finish pass continues past the start location by the value you enter, and
then the lead-out move takes place.

Set Lead In/Out Radius to 0.05 in

This is the radius of the finish walls cutting moves into and out of the material.

Set Helix Clearance to 0.005 in

This works the same as Helix Clearance under the Rough headings, but applies only to
the lead-in and lead-out moves for the Finish Walls cutting passes.

Click OK

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SURFCAM creates the TrueMill toolpath to machine the pocket feature:

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TrueMill® for Step Feature

TrueMill is not limited to closed pockets. You can also machine partially bounded areas often
times called steps, open pockets, or shelves. In other words, the same TrueMill operation can be
used for any 2D removal of bulk material. In this section we will create a TrueMill operation to
machine the Step feature of this part.

Click on NC, 2 Axis, TrueMill

Make sure that the Chain and the Part buttons are depressed

To select the part boundary of the step feature click 1 and 2. The selected chain changes its
color.

Then select the Material button to select the material boundary.

Click 3 and 4.

The selected chain changes its color.

Select Done

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The TrueMill dialog appears:

SURFCAM should default to the same tool and the same machining parameters that were used
for the previous TrueMill operation. If necessary, set the parameters as shown in the previous
section.

Click OK on this dialog box.

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SURFCAM creates the TrueMill toolpath to machine the step:

Important Tip: For clarity, the pocket and the step feature were programmed with separate
operations. TrueMill was designed to program multiple features in one step. Try for yourself by
programming both features with a single operation.

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Toolpath Verification
The SURFCAM verification lets you simulate the cutting operations. To verify the operations you
first need to define the material stock and then run the verification

Follow these steps to specify the material stock:

Open the Operations Manager.

Right click the mouse on Setup One

and select Edit Setup Information

The NC Section Information dialog appears.

Select the Stock tab:

Click the Geometry

Bounding Box button
to automatically
calculate the
coordinates of the
opposite corners of the
material box.

Click Add

Now select OK

Note: the material stock gets saved with the SURFCAM file

Now you are ready to run the verification of the cutting operations.

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Open the Operations Manager dialog

Make sure that Setup One is highlighted

and click on the Run SURFCAM Verify
button

From the verification toolbar select the Play button

The verified part is shown below

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Determining machining parameters for TrueMill

TrueMill was designed to cut faster and deeper than traditional toolpaths. So how do you set the
spindle speed, feed rate, tool engagement and the rest of the machining parameters for your
application? Here is a simple technique to get started.

1. Make straight line test cuts along the outside edge of the material. Start with your usual
cutting parameters except double the tooling manufacturer’s recommended chip load.

2. Monitor the spindle load meter. If load is less than the desired amount, incrementally
increase the Spindle Speed while maintaining the increased chip load from step 1. The
feedrate will therefore increase.

3. Test combinations of increased Spindle Speed, deeper Depth of Cut and/or larger Tool
Engagement Angle until desired spindle load is achieved. Typically with TrueMill, 100%
spindle load can be safely utilized.

4. Use these final parameters in the TrueMill operation page every time you use that specific
combination of machine, cutter, and material – regardless of the shape of the part.

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TrueMill® sample testing results

As a reference, below is data compiled from test parts:

Axial DOC (Ae)

TEA (degrees)
Spindle Speed
Tool Diameter

Programmed
No. of Flutes
Rated HP

Feedrate
Material

Machine Tool Type / Make

Chiron FZ15W Fanuc 18Mi 29 Iscar Carbide Endmill .500 in 3 12000 855 IPM .500 in 120

DMG DMU 50 Heidenhain 17 Iscar Carbide Endmill 12 mm 3 10000* 15000 9 mm 122

TNC530 mm/min

Fadal Cat 40 (year 1983) 20 Kennametal carbide .500 in 3 10000* 400 IPM* .500 in 101
Uncoated, 37° Helix

Fadal Cat 40 (year 1993) 20 Kennametal carbide .500 in 3 10000* 525 IPM* .500 in 100
Uncoated, 37° Helix

Haas VF2 SS 29 OSG Blizzard .500 in 3 12000* 756 IPM .500 in 120
Part #204149

Haas VF2 SS 29 Iscar Carbide Endmill .500 in 3 12000* 840 IPM .500 in 120

Haas VF3 SS 29 OSG Blizzard .500 in 3 12000* 630 IPM .500 in 120
Part #204149

Haas VF3 SS 29 Iscar Carbide Endmill .500 in 3 12000* 825 IPM .500 in 120
Aluminum 6061 T6

Haas VF4 (year 1997) 20 OSG Blizzard .500 in 3 10000* 300 IPM* .500 in 120
Part #204149

Haas VF5 30 Kennametal carbide .500 in 3 7500* 400 .500 in 100

Uncoated, 37° Helix

Haas VM2 20 OSG Blizzard .500 in 3 12000* .500 IPM* .500 in 120
Part #204149 run 200%
ovrd.
Haas VM3 20 Iscar Finishred 12 mm 4 12000* 500 IPM* .500 in 120
run 200%
ovrd.
Hurco VMX 42 24 DataFlute .500 in 3 10000* .500 IPM* .500 in 95
Carbide Endmill

Mazak NEXUS VCM 510C 20 OSG Blizzard .500 in 3 12000* 420 IPM* .500 in 120
Part #204149

Mazak 510C Mazatrol 240 30 DataFlute .500 in 3 14000 600 IPM .500 in 140
ALDH 30500 C5

Mori-Seiki NV4000 DCG 25 Generic bargain .500 in 3 12000* 630 IPM .500 in 120
(VMC) endmill

Mori-Seiki NV4000 DCG 25 Generic bargain .500 in 3 14000* 784 IPM .500 in 120
(HMC) endmill

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Axial DOC (Ae)

TEA (degrees)
Spindle Speed
Tool Diameter

Programmed
No. of Flutes
Rated HP

Feedrate
Material

Machine Tool Type / Make

Cincinati FTV 640 20 DataFlute .250 in 4 7154 65 IPM .350 in 100

27-30 Rc

SSST 40250 C1
Cincinati FTV 640 20 DataFlute .375 in 4 5100 55 IPM .400 in 100
SSST 40375 C1
Cincinati FTV 640 20 Helical 14317 .500 in 4 4200 55 IPM .400 in 100
Steel A2

Makino S56 40 ISCAR 0.625 9000 404 IPM 1.5 56

Steel P20 28-32 Rc

ECI-E5L-625-1.56
C62CF IC900

Kia VX500 20 DataFlute .500 in 4 3100 50 IPM .700 in 120

Carbide Endmill
Steel 1018

Mazak 510C Mazatrol 240 30 DataFlute .500 in 4 5600 80 IPM .500 in 140
SSI 40500 C11

Mazak 510C Mazatrol 240 30 DataFlute .500 in 4 7200 120 IPM .500 in 140
SSI 40500 C11

Haas VM3 20 Iscar Finishred 12 mm 4 12000 500 IPM .500 in 64

Haas VF2 15 Iscar Carbide Endmill .500 in 4 7500 500 IPM* .500 in 36
Steel 1020

Haas VF2 SS 29 Iscar Carbide Endmill .500 in 3 7500* 560 IPM .500 in 27
Steel 1040

Haas VM3 20 Iscar Finishred 12 mm 4 9700 500 IPM .500 in 64

Steel 4140

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Axial DOC (Ae)

TEA (degrees)
Spindle Speed
Tool Diameter

Programmed
No. of Flutes
Rated HP

Feedrate
Material

Machine Tool Type / Make

Haas VF3 20 Iscar ECPI Chip 12 mm 3 5500 396 .375 in 45

Steel 4142

Splitter
E3L 500 -
1.0/1.5C500
IC900

Mazak 510C Mazatrol 240 30 DataFlute .500 in 4 6500 100 IPM .500 in 80
Stainless Steel 420 28 -30 Rc

SSDH 40500 C11

Makino S56 15 OSG EXOCARB 0.75 4 6500 125 IPM .700 in 54

* Indicates a maximum value for this specific machine. SURFCAM Velocity is the first CAM software that will
require machinists to consider their machine’s maximum values.

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